ignition YAMAHA MT-03 2006 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Safe riding .........................................1-1
Protective apparel .............................1-2
Modifications .....................................1-2
Loading and accessories ..................1-2
Gasoline and exhaust gas ................1-4
DESCRIPTION.....................................2-1
Left view ............................................2-1
Right view .........................................2-2
Controls and instruments ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function meter unit ...................3-5
Tachometer .......................................3-6
Odometer, tripmeter modes ..............3-6
Clock mode .......................................3-7
Self-diagnosis devices ......................3-7
Indicator lights brightness
control mode ..............................3-8
Anti-theft alarm (optional) .................3-8
Handlebar switches...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11Brake pedal .....................................3-11
Fuel tank cap...................................3-11
Fuel .................................................3-12
Fuel tank breather/overflow hose ...3-13
Catalytic converter ..........................3-13
Seats ...............................................3-14
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-18
Ignition circuit cut-off system ..........3-19
PRE-OPERATION CHECKS...............4-1
Pre-operation check list ....................4-2
OPERATION AND IMPORTANT
RIDING POINTS..................................5-1
Starting the engine ............................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption ...5-3
Engine break-in .................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR.........................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ..........................6-2
Removing and installing panels ........6-6
Checking the spark plug ...................6-6Engine oil and oil filter element.........6-8
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hoses ...6-13
Adjusting the engine idling speed ...6-14
Checking the throttle cable
free play ...................................6-15
Valve clearance...............................6-15
Tires ................................................6-16
Cast wheels ....................................6-19
Adjusting the clutch lever
free play ...................................6-19
Checking the front and rear
brake pads ...............................6-20
Checking the brake fluid level .........6-21
Changing the brake fluid .................6-22
Drive chain slack .............................6-23
Cleaning and lubricating the
drive chain ................................6-24
Checking and lubricating the
cables .......................................6-25
Checking and lubricating the
throttle grip and cable ..............6-25
Checking and lubricating the
brake and clutch levers ............6-26
Lubricating the brake pedal ............6-26
Checking and lubricating the
sidestand ..................................6-27
Lubricating the side suspension .....6-27
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INSTRUMENT AND CONTROL FUNCTIONS
3-2
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3
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5
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8
9
10
EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and
is used to lock the steering.
NOTE:
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.
EAU36870
ON
All electrical circuits are supplied with
power, the meter lighting, taillight, li-
cense plate light and auxiliary lights
come on, and the engine can be start-
ed. The key cannot be removed.
NOTE:
The headlight comes on automatically
when the engine is started and stays
on until the key is turned to “OFF”,
even if the engine stalls.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removedT
o lock the steering
1. Push
2. Turn
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
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EAU15301
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See further down for an expla-
nation of the ignition circuit cut-off sys-
tem.)
INSTRUMENT AND CONTROL FUNCTIONS
3-18
1
2
3
4
5
6
7
8
9
10
3. Tighten the locknut to the speci-
fied torque.
ECA11240CAUTION:
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
EWA10220
WARNING0
This shock absorber contains high-
ly pressurized nitrogen gas. For
proper handling, read and under-
stand the following information be-
fore handling the shock absorber.
The manufacturer cannot be held
responsible for property damage or
personal injury that may result from
improper handling.
Do not tamper with or attempt
to open the gas cylinder.
Do not subject the shock ab-
sorber to an open flame or oth-
er high heat sources, otherwise
it may explode due to exces-
sive gas pressure.
Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
Always have a Yamaha dealer
service the shock absorber.
Tightening torque:
Locknut:
45 Nm (4.5 m·kgf, 32.5 ft·lbf)
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5
6
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8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
EWA10240
WARNING0
The vehicle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been de-
signed to assist the operator in ful-
filling the responsibility of raising
the sidestand before starting off.
Therefore, check this system regu-
larly as described below and have
a Yamaha dealer repair it if it does
not function properly.
3-19
EAU15311
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the side-
stand is still down.
It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system accord-
ing to the following procedure.
EWA10250
WARNING0
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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PRE-OPERATION CHECKS
4-4
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2
3
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5
6
7
8
9
10
ITEM
Instruments, lights,
signals and switches
Sidestand
switchCHECKS
• Check operation.
• Correct if necessary.
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.PAGE
3-3, 3-9
3-20
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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
WARNING0
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAUB1340
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
WARNING0
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure de-
scribed on page 3-20.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “
I”.
ECAB0040CAUTION:
The following warning lights and in-
dicator lights should come on for a
few seconds, then go off.
Neutral indicator light
Turn signal indicator light
High beam indicator light
Engine trouble warning light
Coolant temperature warning
light
Fuel level warning light
Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the
neutral position.
5-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Parking lighting fuse
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Electronic fuel injection fuse
6. Radiator fan fuse
7. Backup fuse
8. Reserve fuses
The main fuse is located under the fu-
el tank. (See page 6-31.)
The fuse box which contains the fuses
for the individual circuits is located un-
der the rider seat. (See page 3-15.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
ECA10640CAUTION:
Do not use a fuse of a higher am-
perage rating than recommended
to avoid causing extensive damage
to the electrical system and possi-
bly a fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
6-32
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7
8
9
10
Specified fuses:
Main fuse:
30 A
Fuse box:
Parking lighting fuse:
10 A
Signaling system fuse:
10 A
Headlight fuse:
20 A
Ignition fuse:
10 A
Electronic fuel injection fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer,
clock and immobilizer):
10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
NOTE:
If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
The drive chain cannot be disas-
sembled.
7. While supporting the brake
caliper bracket, pull the wheel
axle out, and then remove the
wheel.
ECA11070CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU34430
To install the rear wheel
1. Install the wheel and the brake
caliper bracket by inserting the
wheel axle from the right-hand
side.
NOTE:
Make sure that the retainer on the
swingarm is inserted into the slot
in the brake caliper bracket.
Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the
rear sprocket.
3. Install the axle nut, and then low-
er the rear wheel so that it is on
the ground.
4. Adjust the drive chain slack. (See
page 6-23.)
5. Tighten the axle nut to the speci-
fied torque.
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
EAU25870
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
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PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
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9
10
EAU25921Troubleshooting charts
Starting problems or poor engine performance
WARNING0
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
2. Compression
3. Ignition
4. Battery
Check the fuel level in the
fuel tank.
Operate the electric
starter.
Remove the spark plug
and check the electrodes.
Operate the electric
starter.
There is enough
fuel.
There is
compression.
Wet.
The engine turns
over quickly.
There is no fuel.
There is no
compression.
Dry.
The engine turns
over slowly.
Check the
compression.
Check the ignition.
Wipe off with a dry cloth and correct
the spark plug gap, or replace the
spark plug.
The battery is good.
Have a Yamaha dealer check the
vehicle.
Check the battery lead connections,
and charge the battery if necessary.
Open the throttle halfway and
operate the electric starter.
The engine does not start.
Check the battery.
The engine does
not start. Have a
Yamaha dealer
check the vehicle.
Supply fuel.
Have a Yamaha dealer check
the vehicle.
The engine does not start.
Check the compression.
6-40
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SPECIFICATIONS
8-3
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10
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 55 W/60 W x 1
Auxiliary light:
12 V, 3 W x 1
Tail/brake light:
12 V, 5 W/21 W x 1
Front turn signal light:
12 V, 10 W x 2
Rear turn signal light:
12 V, 10 W x 2
Meter lighting:
LED (backlight)
Neutral indicator light:
LED
Turn signal indicator light:
LED
High beam indicator light:
LED
Fuel level warning light:
LEDCoolant temperature warning light:
LED
Engine trouble warning light:
LED
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30 A
Headlight fuse:
20 A
Signaling system fuse:
10 A
Ignition fuse:
10 A
Parking lighting fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer, clock and
immobilizer):
10 A
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